Ballcock

ABSTRACT

A ballcock for use in a toilet tank comprising a base that is adapted to be connected to a water supply, a cap that is attached to the top of the base with the cap having an opening to receive a pilot valve and the cap also having means to receive a hinge piece, a diaphragm which is received and held in place between the base and the cap with the diaphragm having a central opening, a weight tube having a hinge piece and a float tube being telescopically slidable on the weight tube. When the water level within the toilet tank drops, the float pivots downwardly to depress the pilot valve which have the effect of venting the space above the diaphragm to atmosphere. In this condition the water pressure in the supply line urges the diaphragm upwardly, and water now flows in a flow passage within the base to an outlet containing a fitting which divides the flow, permitting the major part (approximately 90 percent) to go directly into the tank with the remainder going via a flexible tubing to an overflow tube (which is a part of the toilet tank). When the desired liquid level is reached within the tank, the float tube is again upright, so that the pilot valve returns to its normally closed position. Fluid pressure quickly builds above the diaphragm until it equals the liquid line pressure below the diaphragm, and at this time the diaphragm returns to its original closed position, and water no longer flows.

United States Patent [191 Esten 1111 3,811,464 [451 May 21,1974

1 1 BALLCOCK [76] Inventor: Harold Esten, 73 Messenger Ln.,

Willingboro, NJ. 08046 22 Filed: July 10, 1972 21 Appl. No.: 270,117

Related U.S. Application Data [63] Continuation of Ser. No. 25,060,April 2, 1970,

Primary ExaminerAlan Cohan Assistant Examiner-David R. MatthewsAttorney, Agent, or Firm-Caesar, Rivise, Bernstein & Cohen [57] ABSTRACTA ballcock for use in a toilet tank comprising a base that is adapted tobe connected to a water supply, a cap that is attached to the top of thebase with the cap having an opening to receive a pilot valve and the capalso having means to receive a hinge piece, a diaphragm which isreceived and held in place between the base and the cap with thediaphragm having a central opening, a weight tube having a hinge pieceand a float tube being telescopically slidable on the weight tube.

When the water level within the toilet tank drops, the float pivotsdownwardly to depress the pilot valve which have the effect of ventingthe space above the diaphragm to atmosphere. In this condition the waterpressure in the supply line urges the diaphragm upwardly, and water nowflows in a flow passage within the base to an outlet containing afitting which divides the flow, permitting the major part (aeg imete ly9Qh 9nQ wfle rsiire tt lintt? the tank with the remainder going via aflexible tubing to an overflow tube (which is a part of the toilettank). When the desired liquid level is reached within the tank, thefloat tube is again upright, so that the pilot valve returns to itsnormally closed position. Fluid pressure 'quickly builds above thediaphragm until it equals the liquid line pressure below the diaphragm,and at this time the diaphragm returns to its original closed position,and water no longer flows.

10 Claims, Drawing Figures MTENTEDIAY 21 m4 INV'ENTOR. HAROLD ESTE NATTORNEYS.

mamenmm 1914 3811,4634

'SHEET 3 0F 3 76 INVENTOR. HAROLD EST E N 44 BY 68 ATTORNEYS.

BALLCOCK This is a continuation of US. Pat. application Ser. No. 25,060,filed Apr. 2, 1970, now abandoned.

This invention relates to a ballcock, and more particularly to aballcock of a new and improved construction. Most ballcocks now in usegenerally include a float that is positioned at a point somewhat remotefrom the off-on mechanism, with the float being secured to the remainderof the ballcock by means of a rod. When the liquid level in the toilettank drops, the level of the float also drops. This causes a downwardpivoting of the rod that has the effect of opening a water valve that isa part of the ballcock mechanism.

Over the years the float rod linkage concept has proven to beunreliable. This has been a consequence of corrosion and/or wear whichinterfered with the free action of the mechanism, generally resulting inthe inlet valve not being completely shut off. Accordingly, this resultsin annoying trickling noises.

It has been recognized in the art as shown in US Pat. No. 3,429,333 andin U.S. Pat. No. 3,3l9,9l3 that the float can be positioned generallyabove the shut-off means, rather than being secured to a rod that islocated in an inclined, remote position with respect to the shut-offmeans. However, such recently developed devices have proved to besomewhat complicated in construction. and therefore have been offered tothe public at a relatively high cost.

It is therefore an object of the present invention to provide a novelballcock that is simply manufactured through the use ofa small number ofmolded parts and other relatively inexpensive components.

Still another object of the present invention is to provide a ballcockwhich achieves essentially an either on" or "off operation thatessentially eliminates the throttling that was inherent in ballcockscommonly in use.

Yet another object of the present invention is to provide a ballcockthat can be easily assembled, and this contributes further to theeconomy of the present invention.

Still another object of the present invention is to provide a ballcockthat can be simply adjusted when it is desired to achieve a particularwater level that is necessary for the proper operation of a toliet tank.

The foregoing as well as other objects of the invention are achieved byproviding a ballcock that is composed largely of a number of moldedparts. The first molded part is a base that is adapted to be connectedto a water supply. The second molded part is a cap that is attached tothe top of the base with the cap having an opening to receive a pilotvalve, and the cap also having means to receive a hinge piece.

A diaphragm is received and held in place between the base and the cap,with the diaphragm having a central opening.

The third molded part is a weight tube that has a separate hinge piece,and there is a fourth molded part which is a float tube that is slidableon the weight tube.

When the water level inthe toilet tank drops, the float pivotsdownwardly to depress the pilot valve which has the effect of ventingthe space above the diaphragm to the tank. The line pressure of thewater acts against the lower surface of the diaphragm, and since it isgreater than the tank pressure, it immediately urges the diaphragmupwardly to-provide an opening through which the water flows to anoutlet in the base.

When the desired liquid level has been reached within the tank, thefloat tube is again upright so that the pilot valve returns to itsnormalclosed position. Fluid pressure quickly builds above the diaphragm untilit equals the liquid line pressure below the diaphragm so that thediaphragm returns to its original closed position, and water no longerflows.

Other objects and many of the attendant advantages of this inventionwill be readily appreciated as the same becomes better understood byreference to the following detailed description when considered inconnection with the accompanying drawings wherein:

FIG. 1 is a cross sectional view of a toilet tank showing the ballcockof the present invention seated in place, and also showingcertain otherconventional elements including a trap refill hose,'an overflow tube andthe inlet line for the water supply;

FIG. 2 is a sectional view taken vertically through the ballcock of thepresent invention;

. FIG. 3 is an enlarged sectional view taken along the lines 3-3 of FIG.2;

FIG. 4 is a sectional view taken along the lines 4-4 of FIG. 3, showingthe ballcock wherein the foat tube is upright, and no water flowssincethe diaphragm is seated in its closed position;

FIG. 5 is a view similar to FIG. 4, but wherein the float tube haspivoted downwardly to depress the pilot valve, and thereby allow thediaphragm-to move upwardly of its seat, and thereby allow water flowthrough an outlet in the base;

FIG. 6 is a sectional view taken along the lines 6-6 of FIG. 4;

FIG. 7 is a sectional view taken along the lines 7-7 of FIG. 4; and

FIG. 8 is a sectional view taken along the lines 88 of FIG. 4.

Referring now in greater detail to the various figures of the drawingwherein like reference characters refer to like parts, there-is shown at10 in FIG. 2 a ballcock which basically comprises a base 12, a cap 14, aweight tube 16 and a float tube 18.

With reference to FIG. 4 it will be seen that the ballcock 10 furtherincludes a diaphragm 20 and a pilot valve 22.

Also, as shown in FIG. 2, the hinge piece 24 connects the cap 14 to theweight tube 16.

The positioning of the ballcock 10 within toilet tank 26 containingwater 28 may be seen from an inspection of FIG. 1. The ballcock 10 isthreadedly received in a compression fitting water inlet pipe 30, andthe usual trap refill tube 32 is provided which connects the watersupply to the overflow pipe 34. Other standard elements shown in FIG. 1include toilet tank'ball 36 and associated rod 38, with the toilet tankclosed with the usual cover 40.

The details of the base 12 may be seen from an inspection of FIGS. 2, 4,5 and 6 wherein base 12 is shown to have a lower threaded area 42 sothatit can be simply received in complementary internal threads formed inthe inlet pipe 30. Moving upwardly along the base 12 there is a circularflange 44 which aids in the seating of the base 12 upon a complementaryflange 46 of the inlet pipe 30 with the usual gasket 48 being employedfor sealing purposes.

The base 12 terminates in an upper ledge 50 that defines a somewhatrecessed area 52 (FIGS. 4 and S) which receives a diaphragm 20 as willbe discussed hereinafter. The recessed area 52 may be viewed inelevation by referring to FIG. 6.

Also visible in FIG. 6 are wrench flats 54 to aid in the tightening ofthe base 12 within the inlet pipe 30. Openings 56 are provided for thepurpose of lightening the mass of the base 12, and three circularopenings 58 are provided in order to receive bolts 60 as are visible inFIGS. 4 and 5.

Also appearing in FIG. 6 is the water inlet chamber 62 and the waterdischarge chamber 64. As can be seen in FIG. 4, so long as the diaphragm20 is seated upon upper rim 66 defining chamber 62, the line watercannot travel from the inlet chamber 62 to the discharge chamber 64. Asfurther shown in FIG. 4, the lower area of the base 12 includes inletsection 68 which narrows by way of inclined wall 70- to' upper chamber72 that communicateswith the inlet chamber 62.

With further reference to FIG. 4 it will be seen that the outlet chamber64 communicates with separately molded discharge tube 74 that is unitarywith a nipple 76 to which refill tube32is secured.

The details of the cap 14 appear in FIGS. 2 to and weighty material thatis contained within the weight tube 16.

The details of the weight tube 16 can be seen with reference to FIG. 2wherein the weight tube includes an integrally molded disk 114 whichtogether with the sides of the weight tube 16 and the base 108 of thehinge piece 24 defines the sealed chamber 116 for. permanent enclosureof sand 112 or other weighty material. the weight tube 16 also includesupper cylindrical walls 118 which are open at the top.

As further shown in FIG. 2, the float tube 18 includes outer walls 120that telescope about the walls 118 of the weight tube 16. The disk 114presents a shoulder 122 upon which is seated the lower edge of the wall120 of the float tube 18. There is also an upper wall 124 of the floattube 18, and an elongated slot 126 is provided in the float tube 18 toassure that water will fill the weight tube 16, and hence less sand isrequired in the weight tube. 1

The diaphragm 20 is best shown in FIG. 7 as it includes a raised outerarea 79 and a somewhat thinner central area 128 which contains a smallopening 130 I for venting purposes as will now be described.

FIG. 8. The cap 14 isbasically cylindrical in shape and includes a lowersurface 78 that bears against raised peripheral area 79 of the diaphragm20 which is in turn positioned against upper rim 66 of chamber 62.

With further reference to FIG. 8 it will be seen that the cap 14includes spaced openings 80v for lightening purposes, as well as a pairof arms 82 from which project inwardly facing hinge pegs 84 forattachment of the hinge piece 24 as will be discussed hereinafter.

With reference to FIG. 5, it will be seen that the cap 14 includesopenings 86 coinciding with the openings 58 in the base 12 to allow thepassage of bolts 60. As

shown in FIGS. 4 and 5, the cap 14 also includes near its top recesses'88 that terminate in the shoulder 90 to I permit the seating of thehead of bolt 60. In this way the cap 14 is secured to the base 12, andthe interposed diaphragm 20 is securely held in place between the cap 14and the base 12.

The cap l4 also includes a lateral opening 92 which communicates with acentral opening 94 through central chamber 96 which in turn communicateswith opening 92. It will be seen that the pilot valve 22 is p0 sitionedin the opening 92 with external actuating pin 98 of pilot valve 22projecting externally of the cap 14. The pilot valve 22 may bethreadedly held within the opening 92.

The internal end of the pilot valve 22 terminates in a nose 100 thatextends into the chamber 96. It will be seen from an inspection of FIGS.4 and 5 that the actuating pin 98 of the pilot valve is depressed bypivoting action-of hinge piece 24 as will be discussed hereinafter.

The hinge piece 24 is shown in FIG. 3 as comprising a pair of arms 102having notches 104 formed therein which embrace the pegs 84 of the cap14. The arms I02 terminate in a rib 106 that is integrally molded with acircular base 108 to which is attached weight tube 16 using epoxy orother adhesives. It will be seen from FIGS. 4 and 5 that a rim IE0 isalso integrally molded with the base 108. The lower edge of the weighttube 16 telescopes about the rim I10 as shown in FIGS. 4 and 5, and aidsin the retention of sand 112 or other FIG. 4 shows the closed positionof the ballcock when the water 28 is at a predetermined high level asshown in FIG. 1. In such a condition, the float tube I8 is buoyed up bythe water into thevertical position as shown in FIG. 1. When the waterlevel in the tank 26 drops, the float tube 18 starts to tilt as allowedby the hinge piece 24 in the manner as shown in FIG. 5. The pilot valve22 may be a conventional tire valve which is placed in the cap 14 solelyto vent chamber 96 and opening 94 above the diaphragm 20 to tankpressure. When this happens-the reduced pressure-now existing abovediaphragm 20 in opening 94 is immediately overcome by the greaterpressure of the inlet water line that is being exerted against theundersurface of the diaphragm 20 in inlet chamber 62. Thus, the centralsec- 9 tion 128 of the diaphragm 20 is immediately bulged upwardly asshown in FIG. 5, and water flow takes place from inlet chamber 62 intooutlet chamber 64 through discharge tube 74 then dividing with somewhatless fill hose 32, and the balance throu glfthe lateral opening 300 ofthe tube 74. In this way the water level in the tank 26 starts to rise.

Since the float tube 18 is telescoped upon the weight tube 16, theheight of the float tube 18 can be raised or lowered as indicated by thedashed line 142 in FIG. 2. In this way, the desired level of the water28 can be adjusted since the water will continue to flow into the tank26 so long as actuating pin 98 of the pilot valve 22 is sufficientlydepressed to vent to the tank the uppermost surface of the diaphragm 20.In other words, actuating pin 98 is spring loaded and therefore normallyurged outwardly to the position of FIG. 4.

Hence, when the float tube 18 is sufficiently buoyed by the rising levelof water 28, the float tube 18 will return to'its initial verticalposition, and thereby allow the actuating pin 98 to return under springpressure to its normal outward position of FIG. 4. When this occurs,

the uppermost surface of the diaphragm 20 is no longer phragm 20 becomesgreater than the upward forces exerted on the under surface of thediaphragm 20 by the line water pressure. Thisoccurs quite smoothly andso the diaphragm 20 smoothly is reseated upon the upper arm 66 ofchamber 62 to return to the initial position of FIG. 4. All water flownow stops, and the level of water 28 in the tank 26 is maintained.

It will be appreciated that when the space above the diaphragm is nolonger vented to the tank, that the greater liquid pressure below thediaphragm will force liquid through the opening in the diaphragm intothe space above the diaphragm. Since, as can be observed from FIG. 4 rFIG. 5, the space above the diaphragm acts upon a greater area of thediaphragm as compared with the smaller portion of the under surface ofthe diaphragm affected by the liquid line pressure, the downward forcequickly becomes greater than the upward force. Thus. the diaphragm isforced to its normal closed position, and liquid flow stops.

lt will be seen from the foregoing description that the presentinvention basically relies upon six molded parts (preferably of nylonalthough other plastics may be used), a diaphragm and a pilot valve.These parts are simply produced or acquired, and the assembly of theseparts occurs rather quickly with the help of relatively unskilled labor.

The ballcock of the present invention has a life prediction greater thanoperational cycles. This is a consequence of extremely lightly stressedparts. and materials which are insensitive to corrosion. Accordingly,for all practical purposes, the life of the ballcock may be consideredto be infinite.

In view of the foregoing it will be appreciated that the presentinvention constitutes a simple and relatively inexpensive solution to along existing problem.

Without further'elaboration, the foregoing will so fully illustrate myinvention that others may, by applying current or future knowledge.readily adapt the same for use under various conditions of service.

What is claimed as the invention is:

l. A ballcock operating in an axial path comprising a base including adiaphragm and a pivoting cap, said base. diaphragm and cap all normallyaxially aligned with respect to each other. said base also having awater inlet chamber and a water discharge chamber with said diaphragminterposed between said chambers to normally isolate the chambers fromeach other, said base including a space above the diaphragm, saiddiaphragm having a relatively small opening, nonaxial means to vent thespace above said diaphragm, including actuating means. a float tubecoupled to said cap and normally axially aligned with said base anddiaphragm and adapted to pivot along with the cap to cause movement ofsaid actuating means when it is desired to allow liquid flow throughsaid inlet chamber to said discharge chamber, said actuating meanscausing the space above said diaphragm to be vented in response to thepivoting of said cap, wherein the liquid pressure below said diaphragmunseats at least a portion of said diaphragm to allow liquid to flowfrom said inlet chamber to said discharge chamber, and whereby, when apredetermined liquid level is reached, said float tube and cap pivotback to their normal axially aligned orientation whereupon saidactuating means are released to cease the venting of the space abovesaid diaphragm so that fluid pressure quickly builds up therein to besufficiently effective to counteract the water pressure below saiddiaphragm and thereby cause said diaphragm to again isolate the chambersfrom one another to prevent further liquid flow.

2. The ballcock of claim 1 wherein said venting means is a tire valve.

3. The ballcock of claim 2 wherein said discharge chamber is connectedto a discharge tube to which a refill hose is attached.

4. The ballcock of claim 2 wherein said base is threaded so that it canbe attached to a water inlet pipe.

5. The ballcock of claim 2 wherein said cap is attached to the top ofsaid base with said diaphragm being disposed under said cap, saiddiaphragm having a thinner central section, including said opening. withsaid central section being adapted to be bulged away from said base toallow liquid flow.

6. The ballcock of claim 5 wherein said cap includes a hinge piece uponwhich a weight tube is positioned, and wherein said float tube ispositioned on said weight tube.

7. The ballcock of claim 6 wherein said float tube is telescopicallyslidable on said weight tube.

8. The ballcock of claim 7 wherein said hinge piece includes a web thatis pivoted by said float tube and said weight tube, with said webcontacting the actuating means asssociated with saidpilot valve duringthe pivoting of said float tube to open said pilot valve.

9. The ballcock of claim 7 wherein said float tube includes a slotpermitting water to enter a portion of saidweight tube. 7

10. The ballcock of claim 9 wherein said weight tube includes acompartment for reception of .sand.

1. A ballcock operating in an axial path comprising a base including adiaphragm and a pivoting cap, said base, diaphragm and cap all normallyaxially aligned with respect to each other, said base also having awater inlet chamber and a water discharge chamber with said diaphragminterposed between said chambers to normally isolate the chambers fromeach other, said base including a space above the diaphragm, saiddiaphragm having a relatively small opening, nonaxial means to vent thespace above said diaphragm, including actuating means, a float tubecoupled to said cap and normally axially aligned with said base anddiaphragm and adapted to pivot along with the cap to cause movement ofsaid actuating means when it is desired to allow liquid flow throughsaid inlet chamber to said discharge chamber, said actuating meanscausing the space above said diaphragm to be vented in response to thepivoting of said cap, wherein the liquid pressure below said diaphragmunseats at least a portion of said diaphragm to allow liquid to flowfrom said inlet chamber to said discharge chamber, and whereby, when apredetermined liquid level is reached, said float tube and cap pivotback to their normal axially aligned orientation whereupon saidactuating means are released to cease the venting of the space abovesaid diaphragm so that fluid pressure quickly builds up therein to besufficiently effective to counteract the water pressure below saiddiaphragm and thereby cause said diaphragm to again isolate the chambersfrom one another to prevent further liquid flow.
 2. The ballcock ofclaim 1 wherein said venting means is a tire valve.
 3. The ballcock ofclaim 2 wherein said discharge chamber is connected to a discharge tubeto which a refill hose is attached.
 4. The ballcock of claim 2 whereinsaid base is threaded so that it can be attached to a water inlet pipe.5. The ballcock of claim 2 wherein said cap is attached to the top ofsaid base with said diaphragm being disposed under said cap, saiddiaphragm having a thinner central section, including said opening, withsaid central section being adapted to be bulged away from said base toallow liquid flow.
 6. The ballcock of claim 5 wherein said cap includesa hinge piece upon which a weight tube is positioned, and wherein saidfloat tube is positioned on said weight tube.
 7. The ballcock of claim 6wherein said float tube is telescopically slidable on said weight tube.8. The ballcock of claim 7 wherein said hinge piece includes a web thatis pivoted by said float tube and said weight tube, with said webcontacting the actuating means asssociated with said pilot valve duringthe pivoting of said float tube to open said pilot valve.
 9. Theballcock of claim 7 wherein said float tube includes a slot permittingwater to enter a portion of said weight tube.
 10. The ballcock of claim9 wherein said weight tube includes a compartment for reception of sand.